CROSS-REFERENCE TO RELATED APPLICATIONThis application claims priority of Chinese Application No. 201210338444.7, filed on Sep. 13, 2012, the disclosure of which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION1. Field of the Invention
The invention relates to an assembling machine and an assembling method, more particularly to an assembling machine for assembling an elongated module into a tubular body and an associated method therefor.
2. Description of the Related Art
A current LED tube typically includes a heat dissipation substrate, a plurality of LEDs mounted thereon, and a tubular glass body. A method for assembling the heat dissipation substrate into the tubular glass body includes manually dispensing an adhesive upon one side of the heat dissipation substrate firstly, and then inserting the heat dissipation substrate into the tubular glass body so that the side of the heat dissipation substrate with the adhesive adheres to an inner surface of the tubular glass body. When the adhesive sets, the heat dissipation substrate is securely fastened to the tubular glass body.
Because the current assembling method for the heat dissipation substrate and the tubular glass body requires manual labor, the method is inefficient and the speed of assembly is relatively slow, thereby increasing the production cost. Further, manually dispensing the adhesive on the heat dissipation substrate may result in a nonuniform coating of adhesive on the heat dissipation substrate, so that the heat dissipation substrate cannot be securely adhered to the tubular glass body. Additionally, manually inserting the heat dissipation substrate into the tubular glass body may scratch a diffusion layer coated on the inner surface of the tubular glass body, thereby damaging the tubular glass body such that it must be discarded. Thus, the defective rate during production is increased.
SUMMARY OF THE INVENTIONTherefore, an object of the present invention is to provide an assembling machine and method that can automatically and securely assemble an elongated module into a tubular body, so that speed of assembly and efficiency thereof can be enhanced, thereby increasing the assembly yield and reducing the production costs associated therewith.
The advantages and effects of the assembling machine and method of the present invention reside in that by using the design of the holding device, the supporting device, the conveying device, the dispensing device, and the control device to automatically assemble the elongated module inside the tubular body, speed of assembly and efficiency thereof can be enhanced, thereby reducing the production costs associated therewith. Further, the elongated module is prevented from scratching the inner surface of the tubular body during assembly, so that discarding of the tubular body due to damage can be reduced, thereby enhancing the production yield. Additionally, by using the dispensing device to replace manual dispensing of the adhesive, the adhesive can be coated uniformly on the joint surface of the elongated module, thereby preventing nonuniform coating of the adhesive.
BRIEF DESCRIPTION OF THE DRAWINGSOther features and advantages of the present invention will become apparent in the following detailed description of the preferred embodiments with reference to the accompanying drawings, of which:
FIG. 1 is an exploded perspective view of a tubular body and an elongated module which are to be assembled using an assembling machine of the present invention;
FIG. 2 is a schematic front view of the assembling machine according to the first preferred embodiment of this invention;
FIG. 3 is a schematic top view ofFIG. 2;
FIG. 4 is a front view similar toFIG. 2, but illustrating the tubular body being positioned on two holding assemblies and the elongated module being positioned on a cantilever;
FIG. 5 is a schematic top view ofFIG. 4;
FIG. 6 is an enlarged fragmentary schematic view ofFIG. 2, illustrating a detailed structure of the holding assembly;
FIG. 7 is a schematic top view ofFIG. 6;
FIG. 8 is a partly sectional view of the first preferred embodiment, illustrating the holding assembly at an original position;
FIG. 9 is a view similar toFIG. 8, but illustrating the holding assembly at a pressing position;
FIG. 10 is an enlarged fragmentary schematic view ofFIG. 4, illustrating a detailed structure of a supporting arm;
FIG. 11 is a schematic top view ofFIG. 10;
FIG. 12 is an enlarged fragmentary schematic view ofFIG. 2, illustrating a detailed structure of a conveying device;
FIG. 13 is a schematic top view ofFIG. 12;
FIG. 14 is an enlarged fragmentary schematic view ofFIG. 4, illustrating a heat dissipation substrate of the elongated module being engaged to a positioning groove of a positioning plate;
FIG. 15 is an enlarged fragmentary schematic top view ofFIG. 14;
FIG. 16 is a schematic view of a light emitting module of the first preferred embodiment;
FIG. 17 is a schematic top view, illustrating the heat dissipation substrate and the light emitting module being disposed on the cantilever of the first preferred embodiment, and illustrating the LEDs of light emitting unit being received in a first receiving groove, the electrical connector being received in a second receiving groove;
FIG. 18 is a sectional view taken along line18-18 ofFIG. 17;
FIG. 19 is a sectional view taken along line19-19 ofFIG. 17;
FIG. 20 is a flow chart, illustrating the steps involved in an assembling method according to the first preferred embodiment of the present invention;
FIG. 21 is an enlarged fragmentary schematic top view of the first preferred embodiment, illustrating how a conveying assembly takes a plate to move to a position corresponding to a first sensor;
FIG. 22 is an enlarged fragmentary front view of the first preferred embodiment, illustrating how a dispensing device dispenses adhesive on a joint surface of the heat dissipation substrate;
FIG. 23 is another enlarged fragmentary schematic top view of the first preferred embodiment, illustrating how the conveying assembly takes the plate to move to a position corresponding to a second sensor;
FIG. 24 is a fragmentary schematic front view of the first preferred embodiment, illustrating the dispensing device being stopped from dispensing the adhesive on the joint surface of the heat dissipation substrate;
FIG. 25 is a view similar toFIG. 23, but illustrating the conveying assembly taking the plate to a position corresponding to a rear limit switch;
FIG. 26 is a view similar toFIG. 24, but illustrating the heat dissipation substrate protruding from a second opening of the tubular body;
FIG. 27 is an enlarged partial sectional view of the first preferred embodiment, illustrating the heat dissipation substrate being inserted into the tubular body and the tubular body being in a default height position;
FIG. 28 is a view similar toFIG. 27, but with the tubular body being moved to a pressed position;
FIG. 29 is a view similar toFIG. 27, but with the tubular body and the adhered heat dissipation substrate being moved to the default height position;
FIG. 30 is a fragmentary schematic front view of an assembling machine according to the second preferred embodiment of the present invention, illustrating a dispenser at a first height position;
FIG. 31 is a fragmentary schematic top view ofFIG. 30;
FIG. 32 is an enlarged fragmentary schematic top view of the second preferred embodiment, illustrating supporting arms of a supporting device at a protruding position;
FIG. 33 is an enlarged fragmentary schematic front view of the second preferred embodiment, illustrating a dispenser at a second height position;
FIG. 34 is a fragmentary schematic front view of another implementation of the second preferred embodiment, illustrating a positioning member being sleeved on a holding portion of the cantilever and abutting against a front end of the heat dissipation substrate; and
FIG. 35 is an enlarged schematic side view of the another implementation of the second preferred embodiment, illustrating the positioning member being secured to the holding portion by screws.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTSThe above-mentioned and other technical contents, features, and effects of this invention will be clearly presented from the following detailed description of two preferred embodiments in coordination with the reference drawings. Through description of the concrete implementation method, the technical means employed and the effectiveness to achieve the predetermined purposes of the present invention will be thoroughly and concretely understood. However, the enclosed drawings are used for reference and description only, and are not used for limiting the present invention.
Before this invention is described in detail, it should be noted that, in the following description, similar elements are designated by the same reference numerals.
Referring toFIGS. 1 and 2, the first preferred embodiment of an assemblingmachine200 according to the pre sent invention is suitable for fixedly assembling anelongated module100 inside atubular body12 so that the resulting assembly may be applicable for use in a light tube. In this embodiment, theelongated module100 includes an elongatedheat dissipation substrate11 that is made of a metal material having good thermal conductivity and that has aplate surface111 and ajoint surface112 opposite to theplate surface111. Thetubular body12 may be a glass tube that has afirst opening121 and a second opening122 at two opposite ends thereof, and opposite inner andouter surfaces123,124.
Referring toFIGS. 3 to 5, in combination withFIG. 2, the assemblingmachine200 comprises abase2, a holdingdevice3, a supportingdevice4, a conveyingdevice5, and adispensing device6. Thebase2 includes abase plate21 extending in a front-rear direction (I) and having afront end23 and arear end24, and a protrudingseat22 protruding from a top surface of thebase plate21. The holdingdevice3 includes at least one holdingassembly30 disposed on the protrudingseat22 between thefront end23 and therear end24 for holding thetubular body12 such that an axis of thetubular body12 is parallel to the front-rear direction (I) and the first andsecond openings121,122 respectively face the front andrear ends23,24. The supportingdevice4 is disposed on thebase plate21 in proximity to therear end24 thereof, and includes a supportingarm41 that is positioned above and spaced apart from the protrudingseat22 and that is extendable into thetubular body12 through thesecond opening122
Thebase2 further includes anelongated slide rail25 disposed on a top surface of the protrudingseat22 and extending in the front-rear direction (I). The conveyingdevice5 includes a conveyingassembly50 that is proximate to thefront end23 and that is slidably connected to theslide rail25. Through the slidable connection of the conveyingassembly50 with theslide rail25, the conveyingassembly50 is slidable in the front-rear direction (I) relative to thebase2. The conveyingassembly50 includes acantilever51 that is disposed above and spaced apart from theslide rail25 for holding theheat dissipation substrate11 such thatdissipation substrate11 faces thecantilever51. Thecantilever51 is movable between a default position (seeFIG. 4) and an extended position (seeFIG. 26). In the default position, thecantilever51 is positioned spaced apart from and in front of thefirst opening121. In the extended position, thecantilever51 extends into thetubular body12 through thefirst opening121, and a portion of theheat dissipation substrate11 protrudes from thesecond opening122 and abuts against the supportingarm41. Thedispensing device6 includes adispenser61 disposed above and spaced apart from the protrudingseat22 and positioned between thecantilever51 and the holdingassembly30. Thedispenser61 is used for dispensing adhesive60 (seeFIG. 22) onto thejoint surface112 of theheat dissipation substrate11. The holdingassembly30 moves thetubular body12 in an up-down direction (II) and between a default height position and a pressed position. The pressed position is lower than the default height position. In the default height position, as shown inFIG. 27, thetubular body12 surrounds theheat dissipation substrate11, and theinner surface123 thereof is spaced apart from thejoint surface112 of theheat dissipation substrate11. In the pressed position, as shown inFIG. 28, theinner surface123 of thetubular body12 is pressed against thejoint surface112 of theheat dissipation substrate11. Hence, thetubular body112 can automatically be adhered to thejoint surface112 of theheat dissipation substrate11, and theheat dissipation substrate11 can be fixedly assembled to theinner surface123 of thetubular body12. By using the assemblingmachine200 to assemble theheat dissipation substrate11 of theelongated module100 and thetubular body12, the speed of assembly is quick and the efficiency is good, thereby enhancing the assembly yield and reducing the production costs thereof.
Referring toFIGS. 6 to 8, in combination withFIG. 4, in this embodiment, the holdingdevice3 includes two holdingassemblies30 disposed on the protrudingseat22 and spaced apart along the front-rear direction (I). Each holdingassembly30 includes apositioning plate31 defining apositioning groove310 for accommodating thetubular body12. Thepositioning groove310 has a V-shaped cross section. Through the V-shaped cross section of thepositioning groove310, thetubular body12 can be positioned stably on thepositioning groove310 and rocking of thetubular body12 can be prevented.
Furthermore, in order to stably position thetubular body12 in thepositioning groove310 and to simultaneously drive movement of thetubular body12 between the default height position and the pressed position, each holdingassembly30 further includes apress plate32 that is connected to and slidable relative to thepositioning plate31 in a left-right direction (III) (seeFIG. 5) and between an original position and a pressing position. Thepress plate32 is manually operated to slide relative to thepositioning plate31. In the original position, as shown inFIG. 8, thepress plate32 is spaced apart from theouter surface124 of thetubular body12. In the pressing position, as shown inFIG. 9, thepress plate32 presses a top end of theouter surface124 of thetubular body12. At this state, each holdingassembly30 can stably move thetubular body12 between the default height position and the pressed position and can prevent thetubular body12 from separating from thepositioning groove310.
With reference toFIGS. 6 to 9, specifically, thepress plate32 includes a U-shapedpress plate body321, and apress member322 disposed on thepress plate body321. Thepress plate body321 is formed with twoelongated guide slots323 that are proximate to a bottom end thereof and that are spaced apart in the left-right direction (III). Eachelongated guide slot323 extends in the left-right direction (III). The holdingassembly30 further includes twofasteners33 that respectively fasten through theelongated guide slots323 and that are secured to thepositioning plate31. Through cooperation of thefasteners33 and theelongated guide slots323, thepress plate32 is limited to slide relative to thepositioning plate31 only in the left-right direction (III). It should be noted that the number of thefasteners33 and the number of theelongated guide slots323 may be modified to one of each which may similarly achieve the aforesaid result. Thepress member322 is secured to a top end of thepress plate body321, for example, by a screw-fastening method. Thepress member322 is made of a plastic material, for example, Teflon (PTFE), and is used to press the top end of theouter surface124 of thetubular body12. Because Teflon is soft and has a low coefficient of friction, friction between thepress member322 and theouter surface124 of thetubular body12 can be reduced during movement of thepress plate32 from the original position to the pressing position to thereby prevent thepress member322 from scratching or abrading theouter surface124 of thetubular body12.
Additionally, each holdingassembly30 further includes a fixedpost34 and a firstpneumatic cylinder35. The fixedpost34 is affixed to one side of the protrudingseat22, for example, by a screw-fastening method. Thepositioning plate31 includes afirst plate portion311, and asecond plate portion312 perpendicularly connected to thefirst plate portion311. Thefirst plate portion311 is formed with thepositioning groove310, and is connected to thepress plate body321 through thefasteners33. Thefirst plate portion311 is slidably connected to aslide rail341 of the fixedpost34. Theslide rail341 is elongated, and extends in the up-down direction (II), as shown inFIG. 6. The firstpneumatic cylinder35 is disposed on a side of the fixedpost34 that is opposite to theslide rail341, is connected to thesecond plate portion312 of thepositioning plate31, and drives movement of thepositioning plate31 and thepress plate32 in the up-down direction (II) to move thetubular body12 between the default height position and the pressed position.
As shown inFIGS. 4,10, and11, the supportingdevice4 further includes astop plate42 fixed to thebase plate21 of thebase2, for example, by a screw-fastening method, and located at a rear end of the protrudingseat22. Thestop plate42 has afront stop surface421 and atop surface422. Thefront stop surface421 is used to stop anopen end125 of thetubular body12 having thesecond opening122 to limit a rearward movement of thetubular body12. The supportingarm41 protrudes frontwardly from thefront stop surface421, and is flush with thetop surface422. When theopen end125 of thetubular body12 abuts against thefront stop surface421, the supportingarm41 extends into thetubular body12 through thesecond opening122.
Referring toFIGS. 12 and 13, the conveyingassembly50 further includes aslide member52 connected to thecantilever51 and slidably connected to theslide rail25 of thebase2. Theslide member52 includes alower plate521 connected to theslide rail25, and anupper plate522 secured atop thelower plate521. Thecantilever51 extends in the front-rear direction (I) (seeFIG. 4). Thelower plate521 and theupper plate522 cooperatively clamped therebetween afront end portion518 of thecantilever51. Theupper plate522 is fixed to thelower plate521 by using a plurality ofscrews523. One of thescrews523 simultaneously fixes theupper plate522 and thefront end portion518 of thecantilever51 to thelower plate521. Through this, thecantilever51 can be stably connected to theslide member52 in a suspended state.
As shown inFIGS. 12 to 15, theheat dissipation substrate11 extends in the front-rear direction (I), and theslide member52 further includes apositioning plate524 pressed abuttingly against thecantilever51 and secured to thelower plate521 in proximity to a rear end thereof by twoscrews525. Thepositioning plate524 is formed with apositioning groove526 for receiving afront end113 of theheat dissipation substrate11. Through this, theheat dissipation substrate11 can be positioned on thecantilever51 with arear end110 thereof extending beyond arear end510 of thecantilever51 and thefront end113 thereof positioned in thepositioning groove526.
The supportingarm41 includes a guide inclined face411 (seeFIG. 2) that inclines frontwardly and downwardly. When thecantilever51 is moved to the extended position, thecantilever51 and theheat dissipation substrate11 extend into thetubular body12, and therear end110 of theheat dissipation substrate11 is pushed upward by the guide inclinedface411 so as to abut against a top end of the supportingarm41 and to position on thetop surface422 of the stop plate42 (seeFIG. 26). Thus, theheat dissipation substrate11, apart from being supported by thecantilever51, has therear end110 supported by the supportingarm41 and thestop plate42 as well, so that theheat dissipation substrate11 can be stably maintained at a horizontal state. Further, when the holdingassemblies30 are driven to move thetubular body12 from the default height position to the pressed position, theinner surface123 of thetubular body12 is ensured to intimately press against and adhere to thejoint surface112 of theheat dissipation substrate11.
It is worth mentioning that because thecantilever51 is in a suspended state, if theheat dissipation substrate11 depends solely on thecantilever51 for support, when the holdingassemblies30 are driven to move thetubular body12 downward to the pressed position, rear portions of thecantilever51 and theheat dissipation substrate11 are likely to bend slightly downward due to downward force of thetubular body12, so that theinner surface123 of thetubular body12 cannot intimately adhere to thejoint surface112 of theheat dissipation substrate11. Therefore, the present embodiment uses thecantilever51, the supportingarm41, and thestop plate42 to cooperatively support theheat dissipation substrate11 to ensure that theinner surface123 of thetubular body12 can intimately adhere to thejoint surface112 of theheat dissipation substrate11 when thetubular body12 is moved downward to the pressed position.
As shown inFIGS. 1 and 16, theelongated module100 of this embodiment further includes alight emitting module13 disposed on theplate surface111 of theheat dissipation substrate11. Thelight emitting module13 includes three light emittingunits131 that are arranged spaced apart from each other along the length of theheat dissipation substrate11. Eachlight emitting unit131 includes arectangular circuit board132 mounted on theplate surface111, and a plurality of light emitting diodes (LEDs)133 disposed in the middle of thecircuit board132 and arranged spaced apart from each other along the length of thecircuit board132. Every two adjacent ones of thecircuit boards132 of thelight emitting units131 have adjacentshort sides134 spaced apart from each other.
A middle one of thelight emitting units131 includes two pairs ofelectrical connectors135 protruding from thecircuit board132 thereof. Each pair of theelectrical connectors135 are spaced apart from each other in the left-right direction (III) and are proximate to a correspondingshort side134 of thecircuit board132. Each of a front and a rear ones of thelight emitting units131 includes a pair ofelectrical connectors135 protruding from thecorresponding circuit board132. The pairs of theelectrical connectors135 of the front and rearlight emitting units131 correspond in position with the pairs of theelectrical connectors135 of the middlelight emitting unit131. Each pair of theelectrical connectors135 of the middlelight emitting unit131 are electrically and respectively connected to the pair of theelectrical connectors135 of the corresponding front or rearlight emitting unit131 by a pair ofbonding wires136, thereby electrically connecting thecircuit boards132 of the front and rearlight emitting units131.
As shown inFIGS. 13,17,18, and19, because theLEDs133 and theelectrical connectors135 of eachlight emitting unit131 protrude from thecorresponding circuit board132, a surface of eachlight emitting unit131 that is opposite to theplate surface111 of theheat dissipation substrate11 is undulated. In order for thecantilever51 to stably hold thelight emitting module13 and theheat dissipation substrate11 while preventing friction between thecantilever51 and the protruding portions (i.e., theLEDs133 and the electrical connectors135) of thelight emitting units131, in this embodiment, thecantilever51 has a holdingsurface511. The holdingsurface511 is formed with afirst receiving groove512 that is indented inwardly from the center thereof and that extends in a direction parallel to the length of thecantilever51, and two pairs of second receivinggrooves513 spaced apart in the front-rear direction (II). Each pair of the second receivinggrooves513 communicate with left and right sides of thefirst receiving groove512. Thefirst receiving groove512 is used to accommodate theLEDs133 of thelight emitting units131. Eachsecond receiving groove513 is used to accommodate twoelectrical connectors135 and thebonding wire136 connected between theelectrical connectors135. Through this, thecircuit board132 of eachlight emitting unit131 can abut intimately against the holdingsurface511 of thecantilever51, so that thecantilever51 can stably hold thelight emitting module13 and theheat dissipation substrate11 while preventing friction between thecantilever51 and the protruding portions of thelight emitting units131.
It should be noted that the number of thelight emitting units131 and the configurations of theLEDs133, theelectrical connectors135, and thebonding wires136 may be modified as necessary and should not be limited to the above disclosed embodiment. Because thecantilever51 can be detachably connected between thelower plate521 and theupper plate522, thecantilever51 may be replaced to correspond to the modified number of thelight emitting units13 and the modified configurations of theLEDs133, theelectrical connectors135, and thebonding wires136, so that the first and second receivinggrooves512,513 of thecantilever51 can coordinate with theLEDs133, theelectrical connectors135, and thebonding wires136 of thelight emitting module13, thereby ensuring intimate abutment of thecircuit board132 of eachlight emitting unit131 with the holdingsurface511 of thecantilever51. Further, in this embodiment, theelongated module100 may only include theheat dissipation substrate11 and without having thelight emitting module13. In this case, thecantilever51 may omit the first and second receivinggrooves512,513, so that theplate surface111 of theheat dissipation substrate11 is in direct contact with the holdingsurface511 of thecantilever51.
As shown inFIGS. 2,3, and4, the conveyingdevice5 further includes adrive mechanism53 disposed on thebase plate21 to drive sliding movement of theslide member52 of the conveyingassembly50. Thedrive mechanism53 includes amotor531, and a threadedshaft532 that is driven to rotate by themotor531 and that extends in the front-rear direction (I). Theslide member52 further includes aside plate527 secured to one side of thelower plate521 and threadedly connected to the threadedshaft532. When themotor531 drives the threadedshaft532 to rotate, the threadedshaft532, in turn, drives theside plate527 to move back and forth in the front-rear direction (I).
The assemblingmachine200 further includes acontrol device7 disposed on thebase2. Thecontrol device7 includes acontrol box71 disposed on thebase plate21, and acontrol unit72 disposed on thecontrol box71.
Thedispensing device6 further includes a holdingframe62 fixed to a front side of thecontrol box71, and a dispensingcontrol unit63 disposed atop thecontrol box71. Thedispenser61 is disposed on and held by the holdingframe62, has a needle-like structure, and contains adhesive60 (seeFIG. 22). The dispensingcontrol unit63 controls the manner in which thedispenser61 dispenses the adhesive60 (i.e., at intervals or continuously), and controls air pressure sent to thedispenser61 so that the pressurized air can push the adhesive60 to flow down and out of thedispenser61. Thecontrol unit72 is electrically coupled to and controls the dispensingcontrol unit63 so that the dispensingcontrol unit63 can drive thedispenser61 to dispense the adhesive60.
Thecontrol device7 further includes afirst sensor73 disposed on thebase plate21 and electrically coupled to thecontrol unit72. The conveyingassembly50 further includes aplate54 disposed on theside plate527 of theslide member52. When theplate54 and thefirst sensor73 correspond in position, thefirst sensor73 generates and sends a signal to thecontrol unit72, which then controls thedispenser61 to start dispensing the adhesive60. It should be noted that theplate54 may be, for example, a sensor board having a chip or a circuit. Thecontrol device7 further includes asecond sensor74 disposed on thebase plate21 and electrically coupled to thecontrol unit72. Thesecond sensor74 is spaced apart from and is disposed rearwardly of thefirst sensor73. When theplate54 and the second sensor79 correspond in position, thesecond sensor74 generates and sends a signal to thecontrol unit72, which then controls the dispensingunit61 to stop dispensing the adhesive60. Through the arrangement of the first andsecond sensors73,79, thedispenser61 can dispense the adhesive60 onto thejoint surface112 of theheat dissipation substrate11 within a predetermined length (i.e., the distance between the first andsecond sensors73,74).
Themotor531 of thedrive mechanism53 is electrically coupled to thecontrol unit72. Thecontrol device7 further includes arear limit switch75 disposed on thebase plate21 and electrically coupled to thecontrol unit72. Therear limit switch75 is spaced apart from and is disposed rearwardly of thesecond sensor74. When theplate54 and therear limit switch75 correspond in position, therear limit switch75 generates and sends a signal to thecontrol unit72, which then controls themotor531 to stop actuation so as to position thecantilever51 at the extended position and to control the holdingassemblies30 to move downwardly thetubular body12 to the pressed position.
Thecontrol device7 further includes atimer76 disposed within thecontrol box71 and electrically connected to thecontrol unit72. Thetimer76 is used to measure a length of time that the holdingassemblies30 and thetubular body12 are in the pressed position. When the length of time reaches a preset value that is preset by thetimer76, thetimer76 generates and sends a signal to thecontrol unit72, so that thecontrol unit72 controls the holdingassemblies30 to move upwardly to place thetubular body12 back to the default height position. This can ensure that after the adhesive60 between thejoint surface112 of theheat dissipation substrate11 and thetubular body12 is set, only then will thecontrol unit72 command the holdingassemblies30 to move thetubular body12 back to the default height position, thereby preventing thetubular body12 from separating from theheat dissipation substrate11 due to unsolidified adhesive.
Thecontrol unit72 controls actuation of themotor531 so as to drive sliding movement of the conveyingassembly50 to thereby move thecantilever51 back to the default position. The control device further includes afront limit switch77 disposed on thebase plate21 at a position spaced apart from and forwardly of thefirst sensor73 and electrically coupled to thecontrol unit72. When theplate54 and thefront limit switch77 correspond in position, thefront limit switch77 generates and sends a signal to thecontrol unit72, which then controls themotor53 to stop actuation to thereby position the conveyingassembly50 at the default position.
Below is a detailed description of an assembling method of the assembling machine, as shown inFIGS. 4 and 20.FIG. 20 is a flow chart, illustrating the steps involved in the assembling method of the assembling machine according to this embodiment. The assembling method includes steps91 to97.
In step91, the conveyingassembly50 of the conveyingdevice5 that holds theelongated module100 is slid rearwardly along the front-rear direction (I), so that theelongated module100 faces thefirst opening121 of thetubular body12 which is positioned on the holdingdevice3.
In step92, thedispensing device6 is actuated to dispense adhesive60 onto thejoint surface112 of theelongated module100 as theelongated module100 is moved rearwardly. Thecantilever51 of the conveyingassembly50 drives the adhesive-coatedelongated module100 into thetubular body12 through thefirst opening121.
In step93, thedispensing device6 is stopped from dispensing the adhesive60 onto thejoint surface112 of theelongated module100.
In step94, movement of the conveyingassembly50 is stopped so that a portion of theelongated module100 protrudes from thesecond opening122.
In step95, the holdingdevice3 is actuated to move downwardly so as to place thetubular body12 in the pressed position, in which theinner surface123 of thetubular body12 is pressed against and adhered to thejoint surface112 of theelongated module100.
In step96, the holdingdevice3 is actuated to move upwardly so as to place thetubular body12 with the adheredelongated module100 in the default height position to thereby separate theelongated module100 from thecantilever51.
Finally, in step97, the conveyingassembly50 is actuated to slide forwardly until thecantilever51 is located at the default position, in which thecantilever51 is spaced apart from and is disposed in front of thefirst opening121.
With reference toFIGS. 4,8,9, and10, before step91, thetubular body12 is first placed in thepositioning grooves310 of the holdingassemblies30 such that theopen end125 of thetubular body12 abuts against thefront stop face421 of thestop plate42 and such that the supportingarm41 extends into thetubular body12 through thesecond opening122. Next, thepress plates32 of the holdingassembly30 are slid along the left-right direction (III) to the pressing position shown inFIG. 9, where thepress plate32 presses against the top end of theouter surface124 of thetubular body12. Further, with reference toFIGS. 17,13, and19, theheat dissipation substrate11 and thelight emitting module13 of theelongated module100 are placed atop thecantilever51, so that theLEDs133 of eachlight emitting unit131 are accommodated in thefirst receiving groove512 and each pair of theelectrical connectors135 interconnected by acorresponding bonding wire136 are accommodated in the corresponding second receivinggroove513 so that thecircuit board132 of eachlight emitting unit131 can abut smoothly against the holdingsurface511 of thecantilever51. Additionally, with reference toFIGS. 14 and 15, thefront end113 of theheat dissipation substrate51 is engaged with thepositioning groove526 so as to position theheat dissipation substrate11 and thelight emitting module13 on thecantilever51, and therear end110 of theheat dissipation substrate51 partially protrudes beyond therear end510 of thecantilever51.
Referring toFIGS. 20 and 21, in combination withFIG. 4 and step91, astart switch70 of thecontrol device7 is pressed, so that thecontrol unit72 actuates themotor531 of thedrive mechanism53, and themotor531 then drives the threadedshaft532 to rotate. Consequently, the conveyingassembly50 is driven by the threadedshaft532 to slide rearwardly, so that theheat dissipation substrate11 and thelight emitting modules13 of theelongated module100 are moved toward near thefirst opening121 of thetubular body12.
When the conveyingassembly50 drives theplate54 to move to a position corresponding to that of thefirst sensor73, thefirst sensor73 generates and sends a signal to thecontrol unit72. Thecontrol unit72 then actuates thedispensing device6 to carry out step92. As shown inFIG. 22, thedispenser61 of thedispensing device6 dispenses the adhesive60 onto thejoint surface112 of theheat dissipation substrate11 as theelongated module100 is continuously moved rearward into thetubular body12, thereby coating thejoint surface112 with the adhesive60. At this step, the dispensingcontrol unit63 may control thedispenser61 to dispense the adhesive60 at intervals or continuously. Because the conveyingassembly50 continually slides rearward in the front-rear direction (I), thecantilever51 carries the adhesive-coatedheat dissipation substrate11 into thetubular body12 through thefirst opening121.
Referring toFIGS. 23 and 24, in combination withFIG. 20, when the conveyingassembly50 drives theplate54 to move to a position corresponding to that of thesecond sensor74, thesecond sensor74 generates and sends a signal to thecontrol unit72, which then controls thedispensing device6 to perform step93, where thedispenser61 of thedispensing device6 stops dispensing the adhesive60 onto thejoint surface112.
Referring toFIGS. 25 and 26, in combination withFIG. 20 and step94, when thecantilever51 along with theheat dissipation substrate11 and thelight emitting module13 is moved until thecircuit board132 of the rearlight emitting unit131 that partially protrudes out of therear end510 of thecantilever51 abuts against the guide inclinedface411 of the supportingarm41, the guide inclinedface411 pushes thecircuit board132 and theheat dissipation substrate11 upward so as to move thecircuit board132 to abut against the top end of the supportingarm41 and thetop surface422 of thestop plate42. When the conveyingassembly50 drives theplate54 to move to a position corresponding to that of therear limit switch75, therear limit switch75 generates and sends a signal to thecontrol unit72, which then controls the motor531 (seeFIG. 21) to stop actuation. At this time, the movement of the conveyingassembly50 is stopped, theheat dissipation substrate11 is positioned such that a portion thereof protrudes from thesecond opening122 of thetubular body12, and thecircuit board132 of the rearlight emitting unit131 abuts against the top end of the supportingarm41 and thetop surface422 of thestop face42.
Referring toFIGS. 27 and 28, in combination withFIG. 20 and step95, thecontrol unit72 actuates the first pneumatic cylinder35 (seeFIG. 6) of each holdingassembly30 to drive thepositioning plate31 and thepress plate32 of the respective holdingassembly30 to move downward along the up-down direction (II). Thepositioning plate31 and thepress plate32 of each holdingassembly30 then move thetubular body12 downwardly to the pressed position shown inFIG. 28. At this time, theinner surface123 of thetubular body12 is pressed against thejoint surface112 so that the adhesive60 coated on thejoint surface112 will adhere to theinner surface123 of thetubular body12. When the holdingdevice3 moves thetubular body12 downwardly to the pressed position, the timer76 (seeFIG. 4) of thecontrol unit7 begins to keep track of the length of time that thetubular body12 and the holdingdevice3 will remain in the pressed position.
Referring toFIG. 29, in combination with FIG.20 and step96, because thetimer76 has a preset value corresponding to the time required for the adhesive60 to solidify or set and to adhere together thetubular body12 and theheat dissipation substrate11. In this embodiment, the preset value is, for example, eight minutes. When the holdingdevice3 and thetubular body12 have been in the pressed position for eight minutes, thetimer76 will generate and send a signal to thecontrol unit72, which then controls the firstpneumatic cylinders35 to drive thepositioning plates31 and thepress plates32 of the holdingassemblies30 to move upward in the up-down direction (II). Thepositioning plates31 and thepress plates32, in turn, move upward thetubular body12 and theheat dissipation substrate11 adhered thereto to the default height position shown inFIG. 29. As a result, theheat dissipation substrate11 and thelight emitting module13 are simultaneously separated from thecantilever51.
Subsequently, with reference toFIGS. 2,3, and20, in combination with step97, thecontrol unit72 actuates themotor531 to drive the threadedshaft532 to rotate. The threadedshaft532 then drives the conveyingassembly50 to move forward in the front-rear direction (I) until thecantilever51 is moved away from thetubular body12. When the conveyingassembly50 drives theplate54 to move to a position corresponding to that of thefront limit switch77, thefront limit switch77 generates and sends a signal to thecontrol unit72, which controls themotor531 to stop actuation. At this time, thecantilever51 is disposed at the default position, in which thecantilever51 is spaced apart from and is in front of thefirst opening121. Afterwards, thepress plate32 of each holdingassembly30 is moved in the left-right direction (III) (seeFIG. 9) to the original position so as to separate thepress member322 of thepress plate32 from thetubular body12. The assembledtubular body12 andelongated module100 can then be removed from thepositioning grooves310 of thepositioning plates31.
FIG. 30 illustrates the second preferred embodiment of an assemblingmachine210 according to the present invention. The assembling method and the principles involved are substantially similar to that described in the first preferred embodiment. The structure of the assemblingmachine210 is slightly different from that of the first preferred embodiment.
As shown inFIGS. 30,31, and32, in this embodiment, thebase2 includes two protrudingseats22 disposed on thebase21 and spaced apart in the left-right direction (III), and two slide rails25 (only one is shown inFIG. 30) respectively disposed atop the protrudingseats22. The holdingdevice3 includes two pairs of holdingassemblies30, each pair of which is used to hold atubular body12. The supportingdevice4 includes aframe43 disposed on thebase plate21 near therear end24 of thebase2, astop plate42′ disposed at a front end of theframe43, two secondpneumatic cylinders44 disposed within theframe43, and two supportingarms41 connected respectively to the secondpneumatic cylinders44. Each of the secondpneumatic cylinders44 drives a respective supportingarm41 to move in the front-rear direction (I) between a retracted position, as shown inFIG. 31, in which the respective supportingarm41 is positioned behind thestop plate42′, and a protruding position, as shown inFIG. 32, in which the respective supportingarm41 extends beyond thestop plate42′. When each supportingarm41 is in the retracted position, eachtubular body12 can be moved directly downward into thepositioning grooves310 of the corresponding pair of the holdingassemblies30, thereby improving efficiency and convenience in positioning eachtubular body12.
The conveyingdevice5 includes two conveyingassemblies50 that are slidably connected to the respective slide rails25. Thelower plates521 of the conveyingassemblies50 are connected to each other through theside plate527. Through this configuration, thedrive mechanism53 can simultaneously drive sliding movement of the two conveyingassemblies50. Thecantilever51′ of each conveyingassembly50 includes a holdingportion514 for holding theheat dissipation substrate11 and thelight emitting module13. The holdingportion514 has a holdingsurface511 for holding thelight emitting module13. Each conveyingassembly50 further includes twopositioning members55 disposed on the holdingportion514 of thecantilever51′ and spaced apart in the left-right direction (III). Each positioningmember55 is peg-shaped and is used for abutment of thefront end113 of theheat dissipation substrate11 thereto so as to position theheat dissipation substrate11 and thelight emitting module13 on the holdingportion514.
With reference toFIGS. 30 and 31, in combination withFIG. 33, the assemblingmachine210 further includes two supportingframes8 disposed respectively on the protrudingseats22. Each supportingframe8 includes two supporting rollers81 (only one is shown inFIG. 33) spaced apart in the left-right direction (III) and abutting against a bottom surface of the holdingportion514. Through the configuration of the supportingrollers81 that support thecantilevers51′ of the respective conveyingassemblies50, thecantilever51′ of each conveyingassembly50 is prevented from sagging when moving theheat dissipation substrate11 and thelight emitting module13 therealong. Additionally, through abutment of the supportingrollers81 against the bottom surface of the holdingportion514, friction therebetween can be reduced. Hence, thecantilever51′ of each conveyingassembly50 can smoothly bring theheat dissipation substrate11 and thelight emitting module13 to move therealong.
As shown inFIGS. 30 and 33, thecantilever51′ of each conveyingassembly50 further includes a protrudingplate515 extending downward from the bottom surface of the holdingportion514 and positioned between the two supportingrollers81, and acontact roller516 pivoted to the protrudingplate515 and protruding from a bottom end thereof. The protrudingplate515 has aninclined end face517 that inclines upwardly and rearwardly and that is connected to the holdingportion514. Thecontact roller516 is positioned near a bottom end of theinclined end face517. A front end of the protrudingplate515 is connected to a rear end of thelower plate521. When theslide member52 drives thecantilever51′ to move rearward in the front-rear direction (I), thelower plate521 provides a force against the protrudingplate515, allowing theslide member52 to more easily drive thecantilever51′ to move. Through the design of theinclined end face517 of thecantilever51′, thecantilever51′ can smoothly pass through thefirst opening121 and enter thetubular body12, and can be prevented from getting stuck at anopen end126 of thetubular body12 having thefirst opening121. Additionally, through abutment of thecontact roller516 with theinner surface123 of thetubular body12, the protrudingplate515 of thecantilever51′ can be prevented from scratching theinner surface123 of thetubular body12. In the present embodiment, the connection of the holdingportion514 and the protrudingplate515 forms a T-shaped profile, but is not limited thereto. The connection thereof may form an arc-shaped or other shaped profile.
As shown inFIGS. 30,31, and33, thebase2 further includes anupright plate26 disposed on thebase plate21, and two spaced-apart slide rails27 disposed on theupright plate26. Each of the slide rails27 extends in the up-down direction (II). The dispensing unit includes two holdingframes62, twodispensers61 respectively disposed on the holding frames62, and two spaced-apart thirdpneumatic cylinders64 disposed on theupright plate26. Each holdingframe62 is slidably connected to arespective slide rail27. Each thirdpneumatic cylinder64 is connected to arespective holding frame62 to drive therespective holding frame62 to move therealong the correspondingdispenser61 between a first height position, in which thedispenser61 is distal from therespective cantilever51′, and a second height position, in which thedispenser61 is proximate to therespective cantilever51′. The second height position is lower than the first height position. When eachdispenser61 is at the first height position, theheat dissipation substrate11 and thelight emitting module13 are more easily placed on the holdingportion514 of therespective cantilever51′, thereby preventing theheat dissipation substrate11 from accidentally bumping thedispenser61 during the placement thereof.
FIGS. 34 and 35 illustrate another implementation of the positioningmember55′ of the conveyingassembly50. The positioningmember55′ is movably sleeved on the holdingportion514 of thecantilever51′ for abutment of thefront end113 of theheat dissipation substrate11 thereagainst. By using twoscrews56 that respectively engage the left and right sides of the positioningmember55′ and that abut against the holdingportion514 of thecantilever51′, the positioningmember55′ can be fixed to the holdingportion514. Additionally, because the positioningmember55′ is movably sleeved on the holdingportion514, and because thescrews56 can adjustably position the positioningmember55′ to a desired position, when thecantilever51′ is used to support a heat dissipation substrate which has a different length, the positioningmember55′ can be adjusted according to the length of theheat dissipation substrate11 and positioned on the holdingportion514. This provides flexibility in the use of the assemblingmachine210.
To sum up, each embodiment of the assemblingmachine200,210 uses the design of the holdingdevice3, the supportingdevice4, the conveyingdevice5, thedispensing device6, and thecontrol device7 automatically assemble theelongated module100 inside thetubular body12, thereby increasing the speed of assembly, enhancing the efficiency thereof and reducing the production costs associated therewith. Further, theheat dissipation substrate11 of theelongated module100 will not scratch theinner surface123 of thetubular body12 during assembly thereof, so that discarding of thetubular body12 due to damage can be reduced, thereby enhancing the production yield. Additionally, by using thedispensing device6 to replace manual dispensing of the adhesive, the adhesive can be coated uniformly on thejoint surface112 of theheat dissipation substrate11, thereby preventing nonuniform coating of the adhesive. Therefore, the objects of the present invention can be achieved.
While the present invention has been described in connection with what are considered the most practical and preferred embodiments, it is understood that this invention is not limited to the disclosed embodiments but is intended to cover various arrangements included within the spirit and scope of the broadest interpretation so as to encompass all such modifications and equivalent arrangements.